Storage container with blow molded inverted rim and ergonomic handle

ABSTRACT

A storage container includes a bottom wall, a pair of side walls extending up from the bottom wall, and a pair of end walls extending up from the bottom wall, the bottom wall, side walls, and end walls being interconnected and defining a cargo space. A side rim is disposed on top of the side walls and includes a bottom portion extending outwardly from the side wall and an arch extending upward and downward from the bottom portion. The arch defines a convex upper surface and a concave interior arch surface. A middle portion extends upwardly from the arch, an upper portion extends inward from the middle portion, and a lip extending downward from the upper portion and outside of the cargo space. A plurality of spaced apart ribs extend downward from and traverse the concave interior arch surface.

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application60/382,749, filed May 23, 2002.

TECHNICAL FIELD

[0002] An improved reusable plastic storage container is disclosed. Morespecifically, a blow molded reusable plastic storage container isdisclosed which includes one or more of an inverted upper rim spacedlaterally outside of the interior storage space and an ergonomicallydesigned handle.

DESCRIPTION OF RELATED ART

[0003] Reusable storage containers are known. One common type ofreusable storage container is fabricated from molded plastic in the formof an open-top box with a molded plastic lid. Such containers come in avariety of styles and colors.

[0004] Reusable plastic storage containers are typically made from oneof two processes—injection molding or blow molding. An example of aninjection molded reusable storage container is illustrated in FIGS. 1and 2. FIG. 1 is a partial sectional view of a container 30 defining acargo space 32 with a bottom panel 34 connected to a side panel 36which, in turn, is connected to a continuous outer rim 38. The rim 38extends laterally outward from the side panel 36 and cargo space 32. Ahorizontal surface 40 is provided for engaging a top (not shown) and adownwardly protruding lip 42 can be used either to engage a lid latchingmechanism or as a grip or handle. Due to the structure of the rim 38and, specifically, the thickness of a lateral portion 44 (see FIG. 2),the container 30 must be fabricated using an injection molded process.While injection molding is suitable for providing high quality reusablestorage containers, injection molding is relatively slow and not costeffective.

[0005] Blow molding is faster than injection molding but, as shown inFIGS. 3-5, blow molded designs present a different set of problems. Afirst blow molded reusable storage container 50 is illustrated in FIG.3. The container 50 includes a bottom panel 52, connected to a sidepanel 54 which, at its upper end, includes a continuous outer rim 56.The outer rim terminates at an inwardly extending lip 58 which isdisposed laterally inward from at least one portion of the side panel 54and therefore infringes on the amount of available storage spaceprovided by the container 50. Further, the inwardly extending lip 58 issharp and therefore can scratch or cause injury to the user's hands orto material being stored in or removed from the container 50. Further,the structure of the rim 56 does not lend itself to an acceptablesealing engagement with a top or lid (not shown). Also, a blow moldedcontainer heretofore could not achieve a lip as in FIGS. 1 and 2.

[0006] A second blow molded storage container 60 is shown in FIGS. 4-5.The second container 60 includes a side panel 62 connected to an upperrim 64 which changes in configuration as it extends around the foursides of the container. The smaller configuration is shown at 64 a.Again, both rims 64, 64 a terminate at inwardly extending lips 66 which,although avoiding extending into the available storage space, the lips66 are sharp and therefore ergonomically undesirable.

[0007] Further, currently available reusable storage containers do notinclude ergonomically acceptable handles. Specifically, handlesavailable with currently available reusable storage containers are oftendifficult to grasp and do not allow enough space for fingers to graspthe handle. The handles may include sharp edges or pinch points whichcan dig into the user's hand and cause discomfort, especially given thefact that most reusable storage containers have a five gallon or greatercapacity and, when laden with heavy objects such as books, are heavy anddifficult to the move.

[0008] Further, reusable storage containers with handles must befabricated with an injection molding process as current technology ordesigns have not been developed which would enable a suitable handle fora five gallon or greater size container using a more efficient blowmolding process.

SUMMARY OF THE DISCLOSURE

[0009] A more economical and ergonomic reusable three-dimensionalstorage container is disclosed that can meet the need for a plasticreusable storage container that can be manufactured using a more costefficient process than injection molding but that avoids the limitationsand problems presented by previous blow molding designs. Further, thedisclosed storage container meets the need for an ergonomically designedhandle that can be manufactured using a more cost efficient process thaninjection molding.

[0010] One disclosed storage container comprises a bottom panelconnected to and disposed between two opposing side panels and twoopposing end panels. Each side panel is disposed between and connectedto the opposing end panels to form an open top box structure with aninterior storage space. The two opposing side panels and two opposingend panels form a continuous upper rim. The upper rim provides an upperflat engagement surface that terminates in a downwardly protruding lip.More specifically, the upper rim comprises a lower section, a middlesection and a top section. The lower section is connected to one of theopposing end or side panels and extends laterally away from the panel orthe cargo space before being connected to the middle section. The middlesection extends upward from the lower section to the upper section. Theupper section extends laterally inward towards the storage space thatterminates at a downwardly protruding lip disposed laterally outwardfrom a point of connection between the lower section and side or endpanel and laterally outward from the storage space defined by the sideand end panel. The lip protrudes downwardly as opposed to laterally andtherefore does not normally engage a user's hands or the goods beingplaced into or removed from the container.

[0011] In a refinement, the upper rim along the side panel includes anarch that opens downward in between the lower section and the uppersection. A plurality of ribs can be disposed within the arch to providestrength and stability to-the rim.

[0012] In a refinement, the storage container also includes handlesdisposed on the end panels. Each handle comprises a hollow tube with twoends connected to its respective end panel. A portion of the hollow tubeis spaced apart from the respective end panel defining a finger spacedisposed between the hollow tube and the end panel. The portion of thehollow tube that is spaced apart from the end panel has a smooth profilewith no sharp edges which would cause discomfort when lifting thecontainer when it is full of heavy articles.

[0013] In a refinement, the upper section of the rim is substantiallyhorizontal to provide an engagement or sealing surface with a top orlid.

[0014] The containers may be formed by a blow molding process, acontinuous blow molding process or a co-extrusion blow molding process.In a further refinement, the container is fabricated from a polymericmaterial selected from the group consisting of polypropylene,polyethyleneterepthalate, polyvinylchloride, polycarbonate and mixturesthereof.

[0015] Other advantages of the disclosed container and methods will beapparent to those skilled in the art from a review of the followingfigures and detailed description taken in conjunction with the appendedclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The disclosed containers are described diagrammatically in thefollowing drawings wherein:

[0017]FIG. 1 is a partial sectional view of a reusable storage containermade by a conventional injection molding process;

[0018]FIG. 2 is an enlarged sectional view of the upper rim of thecontainer shown in FIG. 1;

[0019]FIG. 3 is a partial sectional view of a reusable storage containermade by a conventional blow molding process;

[0020]FIG. 4 is a partial sectional view of a reusable storage containermade by a conventional blow molding process;

[0021]FIG. 5 is another sectional view of the upper rim of the containershown in FIG. 4;

[0022]FIG. 6 is an elevational view of a blow molded reusable storagecontainer made in accordance with this disclosure;

[0023]FIG. 7 is a top view of the storage container shown in FIG. 6;

[0024]FIG. 8 is an end view of the storage container shown in FIG. 6;

[0025]FIG. 9 is a fragmentary cross-sectional view of the handle andupper rim of the storage container taken along line 9-9 in FIG. 8.

[0026]FIG. 10 is a perspective view of the handle section in FIG. 8,partially cut away.

[0027]FIG. 11 is a fragmentary elevational view from inside of the blowmolded reusable storage container of the upper rim of the storagecontainer, taken along line 11-11 in FIG. 7.

[0028]FIG. 12 is a fragmentary cross-section view of the side rim of thestorage container taken along line 12-12 in FIG. 11.

[0029]FIG. 13 is a fragmentary cross-sectional view of the side rim ofthe strorage container taken along line 13-13 in FIG. 11.

[0030]FIG. 14 is a fragmentary cross-sectional view of the side rim ofthe storage container taken along line 14-14 in FIG. 12.

[0031]FIG. 14a is a perspective view of a portion of the side rim,viewed from underneath and particularly showing the ribbing, of thestorage container.

[0032]FIG. 15 is a perspective view of a movable blow-molding apparatusconfigured to produce the storage container, the moving section being inthe raised position.

[0033]FIG. 16 is a front elevational view of the apparatus of FIG. 15.

[0034]FIG. 17 is a front view of the moving section of the apparatus.

[0035]FIG. 18 is a fragmentary cross-sectional view taken along line18-18 in FIG. 16, and showing the side rim forming portion.

[0036]FIG. 19 is a fragmentary cross-sectional view of the handleforming portion of the mold, the moving section being in a loweredposition, after receiving the resin, and taken along circle 19 in FIG.15.

[0037]FIG. 20 is a fragmentary cross-sectional view of the handleforming portion of the mold, the moving section being in a raisedposition, after the molding process is complete, and taken along circle19 in FIG. 15.

[0038]FIG. 21 is a fragmentary cross-sectional view of the side rimforming portion of the mold, the moving section being in a loweredposition, after receiving the resin, and taken along circle 21 in FIG.16.

[0039]FIG. 22 is a fragmentary cross-sectional view of the side rimforming portion of the mold, the moving section being in a raisedposition, after the molding process is complete, and taken along circle21 in FIG. 16.

[0040]FIG. 23 is a fragmentary cross-sectional view of the side rimforming portion of the mold, the moving section being in a loweredposition, after receiving the resin, and taken along circle 21 in FIG.16.

[0041]FIG. 24 is a fragmentary cross-sectional view of the side rimforming portion of the mold, the moving section being in a raisedposition, after the molding process is complete, and taken along circle21 in FIG. 16.

[0042] The drawings are not necessarily to scale and that theembodiments are sometimes illustrated by graphic symbols, phantom lines,diagrammatic representations and fragmentary views. In certaininstances, details which are not necessary for an understanding of thedisclosed containers or which may render other details difficult toperceive may have been omitted. It should be understood, of course, thatthe disclosure is not necessarily limited to the particular embodimentsillustrated herein.

DETAILED DESCRIPTION

[0043] General

[0044] A reusable storage container 70, constructed in accordance withthe teachings of this disclosure, is illustrated in FIGS. 6-14.Referring to FIGS. 6-8, the container 70 includes a bottom panel 72disposed between and connected to opposing side panels 74, and includestwo opposing end panels 76. The side panels 74, bottom panel 70, and endpanels 76 define a cargo space 78 therein. The container 70 alsoincludes handles 80 extending out from the end panels 76. The end panels76, as well as the side panels 74, may include a number of recesses 82and/or ribs (not shown). The ribs and recesses 82 enhance the structuralintegrity of the container 70 and also enhance the stackability of thecontainer 70 with other like containers 70. Further, any one or more ofthe recesses 82 may also provide a transparent window (not shown) whichenables the consumer to view the contents of the container 70 withoutremoving a top or lid or moving the container 70 from a shelf or otherstored position.

[0045] Rim

[0046] The tops of the respective two opposing side panels 74 and twoopposing end panels 76 form a continuous, inverted upper rim 84. In theregion of the handles 80, the upper rim 84 takes on the configuration ofthe end rim 86, shown in cross section in FIG. 9. On the side panels 74,the upper rim 84 takes on the configuration of the side rim 88, shown ina front view in FIGS. 11 and 14, in cross-section in FIGS. 12 and 13,and in perspective in FIG. 14a. Thus, the end rims 86 and side rims 88are portions of the upper rim 84.

[0047] Referring now to FIG. 9, each end rim 86 includes an end lowersection 90 connected to one of the respective end panels 76 atconnection point or joint 92. The end lower section 90 extends generallyoutward in an angled fashion and away from the cargo space 78 beforebeing connected to an end middle section 94. The end middle section 94extends generally upward from the end lower section 90 before beingconnected to an end upper section 96, and includes a first middlesection 98 and a second middle section 100. The end upper section 96extends generally laterally inward toward the cargo space 78 andterminates in a downwardly protruding lip 102. The lip 102 can bepositioned at or laterally outward from the joint 92 where the end lowersection 90 of the end rim 86 is connected to one of the end panels 76.

[0048] The end rim 86 provides a flat upper engagement surface 104 inthe end upper section 96 for sealing against a top or a lid 106.Further, by including the lip 102 in a downwardly extending position,spaced outward relative to a plane of the end panels 76 and away fromthe cargo space 78, the lip 102 not only does not infringe on theavailable storage space but its generally vertical downward orientationprevents the lip 102 from scratching or otherwise engaging the user'shands or arms or the material being stored in or removed from thecontainer 70.

[0049] The end rim 86 further includes a lid receiver 108. The lidreceiver 108 may be a recess in the end middle section 94. The lid 106may include a protrusion 110 adapted to extend into the receiver 108,thereby holding the lid 106 under tension in the lid receiver 108 andagainst the upper engagement surface 104 and sealing the cargo space 78.The lid 106 can also include a tab 112 such that a user can grasp thelid tab 112, pull the protrusion 110 out of the receiver 108, and removethe lid 106 from the container 70 to reveal and access the cargo space78.

[0050] Referring now to FIG. 11, the inside of a side panel 74, showingespecially the side rim 88, is depicted. As can be seen in FIGS. 12 and13, the side rim 88 includes a side lower section 116 connected to oneof the respective side panels 74 at a transition point or curve 118. Theside lower section 116 angles generally outward from the cargo space 78.

[0051] Connected to the side lower section 116 is a ribbed section 120.The ribbed section 120 includes an arch 122 that extends upward from theside lower section 116 and back down again. As seen in FIGS. 12 and 13,the arch 122 includes a convex surface 124. As seen in FIG. 13, the arch122 includes a concave surface 126, and a top point 128 on the concavesurface 126. A spaced apart series of ribs 130 (seen best in FIG. 13 and14 a) are disposed along the length of and interior to the arch 122 asit traverses the upper rim 84 on its concave surface 126 and extend in adownward fashion from the top point 128. The ribs 130 are orientedgenerally perpendicular to the concave surfaces 126 of the arch 122 andtraverse the area within the arch with plastic or resin 132 and serve toincrease the strength of the upper rim 84.

[0052] The ribbed section 120 is connected to a side middle section 134.The side middle section 134 extends generally upward from al ledge 135which extends outward from a lower outer end of the ribbed section 130.The side middle section 134 further includes a shoulder 138 that extendsinward. A side upper section 136 is connected to the side middle section134. The side upper section 136 extends generally inward back toward thecargo space 78 and defines a flat upper engagement surface 140 andterminates in a downwardly protruding lip 142. The lip 142 can bepositioned at or laterally outward from the transition point or curve118 where the side lower section 116 is connected to one of the sidepanels 74. Again, by including the downwardly protruding lip 142 in aposition spaced outward from the plane of the side panels 74 and awayfrom the cargo space 78, the lip 142 not only does not infringe on theavailable storage space but its generally vertical downward orientationprevents the lip 142 from scratching or otherwise engaging the user'shands or arms or the material being stored in or removed from thecontainer.

[0053] The lid 106 can be disposed on the upper rim 84 in a state oftension to effectively seal the cargo space 78. Accordingly, it isnecessary that the upper rim 84 have enough strength such that it doesnot buckle inward under the tension of the lid 106 or under the weightof the contents of the container 70. The ribs 130 add enough strength tothe upper rim 84 to protect against this occurrence.

[0054] Handles

[0055] The blow molded container 70 further includes ergonomic handles80 as detailed in FIGS. 7, 9 and 10. Each handle is essentially acurved, hollow, open-ended tubular extension of the end panels 76 andhas connection portions 144 extending outward from each end panel 76.Each handle 80 also has a hollow grip portion 146 disposed between theconnection portions 144. The grip portion 146 includes an outside 148, abottom side 150, a top side 152, an upper inside portion 154, and alower inside portion 156.

[0056] Finger spaces 158 are defined by the distance between the endpanels 76 and the grip portion 146 of the handles 80. The finger space158 can preferably have a gap G between the end panel 76 and the gripportion 146 ranging from about 1.25 inches to about 1.50 inches. Thelength of the grip portions 146, can preferably be from about 3 to about8 inches. The circumference of the grip portion 146 can preferably befrom about 2 to about 4 inches. It has also been found that anergonomically preferred handle 80 includes a grip portion 146 that has awidth w that is slightly larger than its height h.

[0057] Further, it is preferred that the handles 80 not include anysharp corners or edges, such as flashing, which would otherwise causepinch points. A smooth exterior surface to the grip portion 146 ispreferred. Some consumers may prefer that the handles 80 not extendoutward from the end panels 76 to a great extent as they couldunnecessarily consume storage space. The above dimensions have beenfound preferable for ergonomic reasons. However, the dimensions can varyaccording to different consumers' tastes, for reasons such as size,style, and the like.

[0058] Mold

[0059] The storage container 70 described herein can be manufactured viablow molding with a molding apparatus 160, as shown in FIGS. 15-24. Themold 160 has a first half 162 and a second half 164. The first half 162is depicted in FIG. 15. The second half 164, seen in a side view in FIG.18 joined to the first half 162, is a mirror image of the first half162. The two halves are joined together by butting the butt face 166 ofthe first half 162 against a corresponding butt face of the second half164. The mold halves can be located by posts (not shown) extending fromthe first butt face 166 being inserted into locator holes in the secondhalf 164, as is known. When referencing the mold 160 hereinafter, itwill be understood that both mold halves are being described, unlessotherwise mentioned.

[0060] The mold 160 includes a frame 170 to which is mounted a fixedsection 172 and a moving section 174. The moving section 174 is movableup and down from a lowered position to a raised position during themolding process in an X direction by a cylinder 178 within guides 180,as will be described in detail later. As seen in FIG. 9, both the movingsection 174 and the frame 170 may include wear plates 182 that bear oneach other to decrease the friction and provide an inexpensive componentthat may easily be replaced instead of replacing the entire movingsection 174 or frame 170.

[0061] The moving section 174 generally includes a tub section 184 and apair of bottom inserts 186 mounted to the tub section 184. The tubsection 184 includes a bottom face 188, a pair of end faces 190, and aside face 192 that provide a surface for which the resin 132 may beblown against to generally form the bottom panel 72, end panels 76, andside panels 74 of the storage container 70. The bottom face 188, the endfaces 190, and the side face 192 can include relief holes (not shown)such that air inside the mold 160 can escape to the atmosphere, andfurther can function as a conduit for a vacuum such that a label can beheld fast in the mold via vacuum pressure during the molding process tocreate an in-mold label or in a surface of the finished product.

[0062] Mold of End Rim

[0063] Referring to FIGS. 19 and 20, the following describes theelements of the moving section 174 and the fixed section 172 that canform the handle 80. Disposed at the top edge of the end faces 190 on thetub section 184 is an end lower face 194. The end lower face 194provides a surface for the end lower section 90 of the end panel 76 andextends generally angularly outward away from the interior of the mold160. The tub section 184 then extends laterally away from the center ofthe mold 160, providing a bottom insert receiver 196. Next to the bottominsert receiver 196 on the tub section 184 is a grip bottom face 198.The grip bottom face 198 is the surface that defines the grip bottomside 150 of the handle 80. Disposed next to the grip bottom face 198 isan end tub flash receiver 200. The end tub flash receiver 200 is adaptedto receive and trap excess the excess resin 132 or flash 201 in the mold160. The moving section 174 then extends downward to define a slidingportion 202.

[0064] The bottom insert 186 is mounted to the bottom insert receiver196. The bottom insert 186 includes an inside face 204 that provides asurface for the first middle section 98 of the end rim 86 to be formedduring the molding process. The bottom insert 186 also includes a cutplate 206 that aids in defining the finger space 158 in the handle 80,as will be detailed later. Finally, the bottom insert 186 includes anoutside face 208 that provides a surface for the grip lower insideportion 156 of the handle to be formed.

[0065] Referring back to FIG. 15, the fixed section 172 is fixedlyattached to the frame 160. The fixed section 172 includes a supportsection 210, a knife section 212, a handle insert 214, both attached tothe support section 210, and an upper finger insert 216 mounted to thehandle insert 214. Again referring to FIGS. 19 and 20, the supportsection 210 and the handle insert 214 define a sliding face 218 uponwhich the sliding portion 202 of the tub section 184 slides.

[0066] Disposed within the fixed section 172 is the handle insert 214.The handle insert 214 is adapted to form the grip outside 148 and thegrip top side 152 of the handle 80, as well as the flat upper engagementsurface 104 of the end upper section 96 of the end rim 86. The handleinsert 214 includes an upper flash receiver 220, which is adapted towork with the end tub flash receiver 200 of the moving section 174 tocontain any extra resin 132 within the mold 160. Next to the upper flashreceiver 220 is the grip outside face 222, which transitions to the gripupper face 224. The grip outside face 222 and the grip upper face 224provide surfaces to create the grip top side 152 and the grip outside148.

[0067] Mounted to the handle insert 214 is the upper finger insert 216.The upper finger insert 216 includes a grip inside face 226 thatcorresponds to the grip upper inside section 154. On the bottom side ofthe upper finger insert 216 are first edge 228, a second edge 230, and athird edge 232. The three edges 228, 230, 232 interact with the cutplate 206 of the bottom insert 186 such that the finger spaces 158 arecut out, as will be detailed later.

[0068] The upper finger insert 216 also includes an inside face 234which provides a surface for the resin 132 to be molded into the secondsection 100 of the end middle section 94. Finally, the upper fingerinsert 216 includes a protrusion 236 that forms the lid receiver 108 inthe end middle section 94. Thus, the inside face 204 of the bottominsert 186 and the inside face 234 of the upper finger insert 216combine to form the middle section 94 of the end rim 86.

[0069] The handle insert 214 also includes an upper face 238 that formsthe upper section 96 of the end rim 86. Further attached to the supportsection 210 is the knife section 212. The knife section 212 includes alip face 240 extending down and in to the mold 160, and a top edge 242.The lip face 240 forms the lip 102 of the end rim 86, and the top edge242 creates a thin portion 244 of the resin 132.

[0070] Mold of Side Rim

[0071] With regard to FIGS. 17, 18, and 21-24, the forming of the siderim 88 by the moving section 174 and the fixed section 172 will now bedescribed. Again, the moving section 174 includes a side face 192 thatcorresponds to the side panel 74 of the finished container 70. The sideface 192 is connected to a lower face 246 that angles generally awayfrom the cargo space 78 of the container 70. Extending upward from thelower face 246 is a ridge 248, best seen in FIG. 17. The ridge 248includes a series of slots 250 extending downward. The ridge 248 and theslots 250 define the ribbed section 120 in the container 70, wherein theridge 248 creates the arches 122, and the slots 250 create the downwardextending ribs 130. Extending outward from the ridge 248 is a tub flashreceiving surface 252, and extending downward from the tub flashreceiving surface 252 is a sliding surface 254.

[0072] The sliding surface 254 of the tub section 184 slides against asliding surface 256 of the support section 210. The support section 210includes a support flash receiving area 258 which works in concert totrap the excess material or flash 260. The support section 210 includesa side middle face 262 and a side upper face 264 for forming the sidemiddle section 134 and the side upper section 136, respectively. Again,disposed in the support section 210 is the knife section 212. The knifesection 212 includes the lip face 266 and edge 268. Here again, the lipface 266 forms the downwardly extending lip 142, and the edge 268creates a lesser cross-sectional area 270 of resin 132. Thus, the resin132 can lay across the ridge 248, and can fill up the slots 250 to formthe ribs 130.

[0073] Molding Process

[0074] The storage container 70 in the present example can bemanufactured in the mold 160 by a blow molding process. A parison (notshown) can be extruded continuously. In one example, multiple layers ofresin 132 are heated into a liquid, then are extruded into a mulit-layerparison. It is advantageous to use mulitple layers because it ispossible to use cost-efficient re-ground plastic in one layer, such as amiddle layer, which can then be hidden by an inside and an outsidelayer. Further, the inside layer can be a more expensive, more durablehard plastic, while the outside layer can be made from a more expensivesofter plastic that may be more pleasing for consumers.

[0075] The parison can be made thicker at the top where the uppe rim 84is to be formed by moving a mandrel within the extruder as is known.After the parison is extruded, the first mold half 164 and the secondmold 166 half are brought together, trapping the parison in between. Themoving sections 174 of the mold halves 164, 166 at this point are in thelowered position. An air source such as a blow pin (not shown) can thenbe placed into the mold through a first air inlet 272 and a second airinlet 274 in the fixed section 172 (seen in FIG. 15). In one example,the air source is placed into the first air inlet 272, while an airexhaust is placed in the second air inlet 274. In this manner,pressurized cool air can be continuously inserted into the mold, andexhausted, to ensure that only cool air is inside the mold 160 toincrease the cooling rate of the resin 132 therein. If there was no airexhaust, the air inside the mold 160 would be warmed from the heat ofthe resin, and the cooling rate would be reduced. Further, by limitingthe exhaust rate, the elevated pressure can be maintained in the mold160.

[0076] The pressure from the air pushes the resin 132 of the parisonoutward against the surfaces of the mold 160. Since the moving section174 is in the lowered position, areas of the sliding portions 218, 256of the fixed section also receive part of the resin, as depicted inFIGS. 19, 21, and 23. These same figures depict the resin as it is beingblown outward and prior to the resin 132 contacting the mold surfaces.

[0077] As the pressurized air enters the chamber, the resin 132 is blownagainst the mold surfaces. In FIG. 19, the resin 132 is forced againstthe end surface 190, the end lower face 194, bottom insert inside face204, the sliding portion of the fixed section 218, the finger insertinside face 234. At this point, with the resin 132 still molten, thecylinder 178 is activated, and the moving section 174 is pushed upwardin the X direction, as is shown in FIG. 20. The first, second, and thirdedges 228, 230, and 232 of the finger insert 216 contact the cut plate206 of the bottom insert 186. A volume of flash 260 is captured betweenthe first and second edges 228, 230 of the finger insert 216 and thebottom insert 186. A smaller volume of flash 260 is captured between thesecond and third edges 230, 232 of the finger insert 216 and the bottominsert 186. This smaller volume creates a rigid edge which makes iteasier to cut out the flash 260 from within the finger space 158.

[0078] As the moving section 174 and the fixed section 172 cometogether, resin 132 is forced against the upper grip face 224, theoutside grip face 222, the bottom grip face 198, and the bottom insertoutside face 208, and the grip inside face 226. Further, extra resin 132is caught in the end tub flash receiver 200. By including the end tubflash receiver 200, the resin 132 does not get stretched along theoutside grip face 222 as the moving section 174 closes. Thus,unattractive stretch marks in the end product are avoided. A hollowhandle 80 with a cut-out finger space 158 can thereby be created withthe above blow molding technique.

[0079] The first middle section 98 is joined with the second middlesection 100, and the resin 132 is forced against the upper section face238 of the handle insert 214 by air pressure and by the closing movingsection 172. The knife section 212 creates the lip 102, and the edge 242creates a thin portion 244 of the cooled resin 132. The resin 132 isfurther forced upward into the knife section 212 to create a top piece276. The thin portion 244 makes it easy to cut out the top piece 276away from the storage container 70, to create an open top container 70that can receive a lid 106 for sealing.

[0080] FIGS. 21-24 depict the portion of the mold 160 responsible forcreating the side rim 88. The resin 132 is forced against the side face192 of the tub section 184, the ridge 248 of the tub section 184, andthrough the slots 250 of the ridge 248. The resin 132 is further forcedagainst the sliding portion 256, the middle face 262, and the upper face264 of the support section 210. This can be seen in FIGS. 21 and 23. Asthe moving section 174 moves upward, as in FIGS. 22 and 24, a portion ofthe resin 132 becomes trapped in the support flash receiving area 258.The resin 132 then lays down over the ridge 248 to create the arch 122.The resin 132 further lays in the slots 250. The system may be designedsuch that the support flash receiving area 258 cannot fit all theavailable resin 132 therein. As such, the extra resin 132 is forced outof the support flash receiving area 258 and back into the mold 160 asthe moving section 174 closes. This extra resin 132 then travels intothe slots 250, thereby filling up the slots 250 and creating thedownward extending ribs 130. The side upper section 136 and side lip 142are created in the same manner as in the end upper section 96 and theend lip 102.

[0081] After the parison is fully inflated against the sides of the mold160 and the storage container 70 has been formed, the top piece 276 andflashing 201, 260 remain. In a post-molding operation, this excessmaterial can easily be cut away. The top section can include flatportions that can be used to hold the storage container 70 as the topportion 276 is cut away along the portions of reduced thickness 244,270. The flashing 201, 260 is also cut away, and the resin can bere-ground and re-used in a later operation, or sold to recyclers.

[0082] The foregoing detailed description is given for clearness ofunderstanding only, and no unnecessary limitation should be understoodtherefrom, as modifications within the scope of this disclosure maybecome apparent to those skilled in the art.

We claim:
 1. A storage container comprising: a bottom wall; a pair ofside walls extending up from the bottom wall; a pair of end wallsextending up from the bottom wall, the bottom wall, side walls, and endwalls being interconnected and defining a cargo space; a side rimdisposed on top of the side walls and including a bottom portionextending outwardly from the side wall, an arch extending upward anddownward from the bottom portion and defining a convex upper surface anda concave interior arch surface, a middle portion extending upwardlyfrom the arch, an upper portion extending inward from the middleportion, and a lip extending downward from the upper portion, the lipbeing outside of the cargo space; and a plurality of spaced apart ribsextending downward from and traversing the concave interior archsurface.
 2. A method of manufacturing a storage container, the methodcomprising: closing two mold halves about a parison, the mold halvesincluding a fixed portion and an upwardly movable portion and defining amold cavity; applying air pressure to blow material against surfaces ofthe mold cavity; and moving the movable portion upward during orimmediately after the applying step to form at least one hollow handlegrip and a side rim having an upward extending concave arch with aplurality of spaced apart ribs traversing the concave arch.